TABLE OF CONTENTS CHAPTER 1…….... SPECIFICATIONS ..........................................................................................1 CHAPTER 2…........ PRECAUTIONS ..............................................................................................2 CHAPTER 3………. MACHINE ORIENTATION ...........................................................................3 CHAPTER 4………. GENERAL MAINENANCE ...........................................................................
LIST OF FIGURES Figure 1: Machine Orientation ............................................................................................................ 3 Figure 2: Mounting Foot Detail .......................................................................................................... 4 Figure 3: Entry Guide ......................................................................................................................... 7 Figure 4: Acme Shafts and Left Side Adjustment ......................
LIST OF FIGURES Figure 48: Figure 49: Figure 50: Figure 51: Figure 52: Figure 53: Figure 54: Figure 55: Figure 56: Figure 57: Figure 58: Figure 59: Figure 60: Figure 61: Figure 62: Figure 63: Figure 64: Figure 65: Figure 66: Figure 67: Figure 68: Figure 69: Figure 70: Figure 71: Figure 72: Figure 73: Figure 74: Figure 75: Figure 76: Figure 77: Figure 78: Figure 79: Figure 80: Figure 81: Figure 82: Figure 83: Figure 84: R1 Tooling Rail Spacers.................................................................
LIST OF FIGURES Figure 94: Setup Screen ...................................................................................................................... 7 Figure 95: Status Screen ..................................................................................................................... 7 Figure 96: Security Screen .................................................................................................................. 8 Figure 97: Coils Password Access Screen ......................
CHAPTER 1 SSQ SPECIFICATIONS SPECIFICATIONS SSQ Dimensions: Length-13’ 7” Width-5’ Height-4’ 3” 1’ 10” Weight-2200 lbs. (4.1m) (1.5m) (1.3m) w/Over Head Rack (.6m) w/o Over Head Rack (1450kg) SSQ on Trailer: Length-17’ 6” Width-7’ Height-6’ 3” Weight-4800 lbs. (5.3m) (2.1m) (1.9m) with reel (2200kg) Speed: 75 ft./min. Approx. (23m/min.) Approx. Drive: Hydraulic via chain, sprocket and gear using16 polyurethane drive rollers.
CHAPTER 2 PRECAUTIONS PRECAUTIONS 1. Make sure the operator of the machine has read and understands this manual in its entirety before attempting to operate this equipment. 2. ALWAYS keep covers, guards and lids mounted to machine during operation 3. OBSERVE and OBEY all safety and warning signs affixed to the machine. 4. ALWAYS adhere to and follow all local and national safety codes concerning the loading and un-loading of reeled coils. 5.
CHAPTER 3 MACHINE ORIENTATION MACHINE ORIENTATION Figure 1: Machine Orientation 3
CHAPTER 3 MACHINE ORIENTATION Figure 2: Mounting Foot Detail 4
CHAPTER 4 GENERAL MAINTENANCE GENERAL MAINENANCE 1. Always keep covers on during operation and storage. The covers are for operator safety, but also protect the internal components of the machine from the environment. 2. Avoid storage of the machine outdoors for long periods of time. Cover your machine with a tarp to protect it but provide good ventilation to prevent condensation and rust. 3. Keep your machine clean. This will increase the life of the machine and make maintenance easier.
CHAPTER 4 GENERAL MAINTENANCE Recommended Lubricants and Fluids Spray Lube for: Shear Blades, Dies, Entry Guide, Bead Roller Carriage Shafts, Acme Shafts and Mitre Gears Super Lube - Multi-Purpose Synthetic Dri Film Aerosol Lubricant with Syncolon (PTFE) Catalog No. 11016 11 oz. Aerosol Can Available from: MSC Supply at 1-800-645-7270 Clear Grease for: Arbor Cradles Synthetic Extreme Pressure, High Temperature Grease with Syncolon (PTFE) Catalog No.
CHAPTER 4 GENERAL MAINTENANCE Figure 3: Entry Guide 7
CHAPTER 4 GENERAL MAINTENANCE Figure 4: Acme Shafts and Left Side Adjustment 8
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION ELECTRICAL CONTROLS AND OPERATION POWER CORD REQUIREMENTS For machines equipped with a QCPP-E it is very important to follow the power cord requirement prescribed by the motor and electrical control manufacturers to maintain their respective warranties. Make sure the cord you are using is marked properly. Do not assume that because an extension cord looks heavy enough that it is the right gauge.
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Function #1 (Power On) Pull this button OUT prior to starting the machine. Function #2 (Emergency Stop-Power Off) Once the machine is running, pushing this button in will stop all functions and completely shut down the machine including the engine. If the shear is in the down cycle it will freeze it in position. The shear will default back to the top or home position once the engine or motor is re-started.
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION REMOTE LIMIT SWITCH (See Figure 7) Note: Your machine will not run continuously in the forward direction unless the REMOTE LIMIT SWITCH is plugged into the machine. The Remote Limit Switch is used for panel length control. It is designed to attach to the right side of the optional RUN OUT TABLES available for your machine.
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Figure 5: Controls 12
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Figure 6: Main Control Cable 13
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Figure 7: Run Out Table and Remote Limit Switch 14
CHAPTER 5 ELECTRICAL CONTROLS AND OPERATION Figure 8: Main Control Box Fuse Figure 9: QCPP E 1-6 Fuse Location 15
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS REEL STANDS, REELS AND EXPANDABLE ARBORS EXPANDABLE ARBOR (Figure 10) The Expandable Arbor adjusts to accommodate coils with 16” to 20” inside diameters by expanding into the ID of the coil. THREADED NUT The threaded nut should always be on the right side of the machine and the tail of the coil should always be routed over the top and pointing toward the exit or shear end of the machine.
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS Figure 10: Expandable Arbor Set-Up 17
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS CAUTION: Always use properly rated lifting devices to load and unload coils. Maximum Capacity / Reel: 3,000 lbs. Total Capacity for Reel Stand: 6,000 lbs. 1. The reel shafts must rest in the cradles on the reel rack. Keep the cradles lubricated with synthetic lube to minimize wear. (Figure 11) 2. Use the Hold Down Bars on each cradle to secure the coil and reel to the reel stand during both operation and transit of the machine.
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS Figure 11: Expandable Reel Assembly 19
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS LOADING REELED COIL Caution: Always use a forklift or other approved lifting device to load or unload Fixed Reels or Expandable Arbors loaded with coil. The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier. DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps. 1. 2. 3. 4. 5. Prepare the reel stand by making sure the Hold Down Bars are in the unlocked and open Position (Figure 11).
CHAPTER 6 REEL STANDS, REELS, AND EXPANABLE ARBORS Figure 12: Material Routing 21
CHAPTER 7 HYDRAULIC SYSTEMS HYDRAULIC SYSTEMS Maintenance (Figure 13) The hydraulic system for your machine is a very durable and reliable system. It must be properly maintained to ensure trouble free operation and longevity. The factory has installed a 32 weight AW hydraulic fluid. Because this equipment is used primarily outdoors and exposed to the elements, it is recommended that the oil be changed annually. Hydraulic oil will degrade if it remains stagnate in the system for long periods of time.
CHAPTER 7 HYDRAULIC SYSTEMS 8. Re-install the new hydraulic filter and fill the tank with fresh 32 weight fluid until it is 5” below the top of the Filler Neck “F” (approximately 18 gal).
CHAPTER 7 HYDRAULIC SYSTEMS Figure 14: Hydraulic System – Details 24
CHAPTER 7 HYDRAULIC SYSTEMS Figure 15: Hydraulic Fluid Level 25
CHAPTER 8 DRIVE SYSTEM DRIVE SYSTEM (Figure 16, Figure 17 & Figure 18) The drive system of your machine consists of eight top and eight bottom polyurethane drive rollers. They are divided into groups of 2 per assembly making 4 Top Drive Roll Assemblies and 4 Bottom Drive Roll Assemblies. They are connected together via chain and sprocket and there are chain tensioner’s on each assembly.
CHAPTER 8 DRIVE SYSTEM 5. Clean the rollers with mild soap and water and a rag. Caution must be taken around the moving parts of the machine during the cleaning process. Covers should be kept on the machine during operation and storage. Ultraviolet light will attack the polyurethane drive rollers and cause deterioration. Again, this type of damage is not covered under the warranty.
CHAPTER 8 DRIVE SYSTEM Figure 17: Gears and Shafts 28
CHAPTER 8 DRIVE SYSTEM Figure 18: Chains Upper and Lower 29
CHAPTER 9 SHEAR ASSEMBLY SHEAR ASSEMBLY OPERATION Push the SHEAR DOWN button to activate the shear cycle and cut material. IN CASE OF AN EMERGENCY: Push the SHEAR UP button during the down cycle to immediately send the shear up to the home position. The shear is electrically activated and hydraulically driven. The two Top Limit Switches and single Bottom Pressure Switch control the cycle of the shear. The Top Limit Switches electronically lock out the drive system when the shear is in motion.
CHAPTER 9 SHEAR ASSEMBLY and Female Entry Dies should be 1/32” or less away from the back side of the vertical leg of the panel. The Male and Female Exit Dies should be adjusted slightly to the outside of the entry dies so that the cut edge of the panel clears the dies without interference when passing through after a cut. Once alignment of the dies is achieved, tighten all “C” bolts. Jog the material out approximately 2”. Engage the shear to cut to 2” piece off.
CHAPTER 9 SHEAR ASSEMBLY Figure 20: Shear Die Detail Views 32
CHAPTER 9 SHEAR ASSEMBLY TOP SHEAR BLADE ADJUSTMENT (Figure 19 & Figure 20 – Details B & C) The Top Shear Blades are bolted to the Blade Adjustment Bar. This bar is bolted to the Top Blade Holder, and can be moved from left to right to align the blades to the Die Holders. 1. 2. 3. Loosen the 7 “D” bolts in the slots at the top entry side of the shear so that the Blade Adjustment Bar will move from side to side.
CHAPTER 10 BEAD AND STRIATION ROLLER ASSEMBLY BEAD AND STRIATION ROLLER ASSEMBLY 1. 2. 3. 4. The Bead / Striation Roller assembly (Figure 21) is located behind the shear and is accessed by removing top cover #3. These rollers can be engaged or disengaged as needed and can also be moved left or right to accommodate different panel widths. The bottom bead or striation forming roller should be set 1 /32” above the drive roller to ensure proper entry into the shear.
CHAPTER 10 BEAD AND STRIATION ROLLER ASSEMBLY Figure 21: Bead Roller Assembly 35
CHAPTER 11 ENTRY GUIDE ASSEMBLY ENTRY GUIDE ADJUSTMENT (Figure 22 & Figure 23) The entry guides are used to set the material to the correct position in relation to the forming rollers of the machine. They also hold the material and feed it straight into the machine. If the entry guides are not set correctly the material will not feed into the machine properly. 1. The Right Entry Guide is set to the Tooling Rail Marker Plate mounted to the R1 Tooling Rail. 2.
CHAPTER 11 ENTRY GUIDE ASSEMBLY 7. Slide the Left Entry Guide to the left or right to accept the new coil width. Make sure that the coil is captured snugly between the entry guides and re-tighten the two “A” bolts.
CHAPTER 11 ENTRY GUIDE ASSEMBLY Figure 24: Tooling Rail Adjustment Handle Figure 26: Disengaged Figure 25: Marker Plate & Alignment Pin Figure 27: Engaged 38
CHAPTER 12 CLIP RELIEF ROLLER ASSEMBLY CLIP RELIEF ROLLER ASSEMBLY 1. Clip Relief Rollers (Figure 28) provide a raised area next to the male and female legs of the panel. This helps hide the clip and screws used in installation. They rollers can be engaged or disengaged as needed. 2. Find the Tooling Rail Sheet corresponding to the profile installed in your machine (Figure 59 - Figure 79).
CHAPTER 13 ENTRY DRUM ASSEMBLY ENTRY DRUM ASSEMBLY The Entry Drum Assembly is necessary when feeding coil off of the optional DR1/ Dual Overhead Reel Stand. It allows you to route the material around the drums to get the painted side of the coil on the top as it enters the machine. Without this assembly, you could only feed coil from a remote arbor and stand lined up behind the machine. The Entry Drums need to be adjusted whenever a width change is made. To adjust the entry drums: 1.
CHAPTER 14 WIDTH CHANGE PROCEDURE WIDTH CHANGE PROCEDURE CAUTION: Always make sure your machine is shut down prior to making any adjustments. DO NOT reach through the opening of the shear while the machine is running. EVER! To do so could result in serious injury. 1. Loosen the two “A” bolts on the Left Entry Guide (Figure 30). Slide the entry guide to the left or right to accept the new coil width. Figure 30: Entry Guide Bolts "A" 2.
CHAPTER 14 WIDTH CHANGE PROCEDURE 4. Load material onto the Expandable Arbor and align it to the correct position using the chart on (Figure 31). Note: Also see REEL STANDS, REELS AND EXPANDABLE ARBORS for more information.
CHAPTER 14 WIDTH CHANGE PROCEDURE 5. Load the reeled coil onto the machine using a fork lift or other rated lifting device. Making sure the tail of the coil goes over the top and points toward the shear end of the machine. See coil routing diagram (Figure 12). 6. Cut a 1” triangle of off the 2 leading corners of the coil and feed it into the entry guides. (Figure 32) Figure 32: Loading Material 7.
CHAPTER 14 WIDTH CHANGE PROCEDURE Figure 33: Bead Roller Alignment 8. If you require beads in the panel, determine the spacing needed. For Example: a 12” wide panel with 2 beads centered on the panel would give you 3 equal spaces or 12” divided by 3 equals 4” from center to center of each bead. Hook the end of you tape measure on the outside bottom corner of the female leg. Use a magic marker or grease pencil to mark the 4” and 8” locations on the panel. You now have 3 equal spaces. 9.
CHAPTER 14 WIDTH CHANGE PROCEDURE BOL T "A" BOL T "A" LOCK N UT LOCK N UT BOLT "B" BOLT "B" BOL T "B" BOLT "B" A BOLT "D" HOLE FOR HEX WREN CH SID ES FLU SH PASS LIN E BOLT "C " BOLT "D" D ET AIL A RR 5 OPTION SHOW N Figure 34: Bead Roller Width Change 11. Check the gap between the top and bottom bead rollers using a feeler gauge. An approximate setting of 1½ times the material thickness is recommended. This setting can be adjusted slightly in either direction according to preference. 12.
CHAPTER 14 WIDTH CHANGE PROCEDURE 14. Rotate the top shaft from the 12:00 position toward the shear to decrease the gap, or away from the shear to increase the gap until the feeler gage is captured. 15. Tighten the “C” bolt to lock the position of the shaft. 16. Repeat steps 11through 15for the remainder of the bead rollers. 17. Start the machine, jog the material through the bead assemblies and stop 2 to 3 inches from the entry shear dies. 18. Inspect the beads for depth and re-adjust as necessary.
CHAPTER 14 WIDTH CHANGE PROCEDURE 22. Visually site through the male entry die and rough align it to the forming tool “line of fire” by sliding it left or right. Re-install the two “C” bolts into holes that correspond to the slots. Do not tighten the bolts at this time, just snug them up. 23. Install the male exit die in the same manner aligning it to the entry die and again, just snug the bolts. 24. Start the machine and carefully jog the panel up to the shear.
CHAPTER 14 WIDTH CHANGE PROCEDURE 29. Make sure that one of the points of the top shear blade is inboard of the vertical portion of the male leg. This part of the leg should be cut with the angle or rake of the blade to cut in a scissor action against the vertical die. See TOP SHEAR BLADE ADJUSTMENT (Figure 19 & Figure 20) if adjustment is necessary. 30. Start the machine and press the shear down button to cut off the panel, then jog the material through the shear again and stop. 31.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE PROFILE CHANGEOVER PROCEDURE CAUTION: Always make sure your machine is shut down prior to making any adjustments. DO NOT reach through the opening of the shear while the machine is running. EVER! To do so could result in serious injury. 1. Remove Top Covers number 1, 2, 3, 4, and 5 (Figure 37) and set aside. Figure 37: Remove Top Covers 2. Using a ½” wrench, remove the bolts holding the right and left Tooling Rails to the Fixed Rail Mounts (Figure 38).
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 38: Removing Tooling Rails 3. Refer to the SSQ Slide Block chart (Figure 39) and find the profile you will be installing into the machine. It will tell you if the Right Side Fixed Mount Rail #1 needs to be in the Inboard position or Outboard position (Figure 40). IF THE RAIL IS NOT IN THE CORRECT POSITION, GO TO STEP 4. IF THE RAIL IS IN THE CORRECT POSITION GO TO STEP 6.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 40: Inboard/Outboard Positions 51
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE 4. Loosen bolt “C” on the first 4 Slide Block assemblies (Figure 41 or Figure 42).
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE 5. Once all 4 bolts are loose, slide the Right Side Fixed Mount Rail #1 to the correct position (Figure 43), either “inboard” or “outboard". Make sure that it is fully in position and then tighten the “C” bolts (Figure 41 or Figure 42). Figure 43: Right Side Fixed Mount Rail 6. Locate your profile in the chart below to see what position the Left Side Fixed Mount Rail #1 needs to be in.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 45: Left Side Fixed Mount Rail Figure 46: Shown in the “A” position 7. Find the R1 Tooling Rail and set it flat on top of the Right Side Fixed Mount Rail #1 making sure the correct number shows in Sight Hole “C” (Figure 47). Thread the two mounting bolts into the slots of the rail and finger-tighten them. Pull the Tooling Rail assembly toward the outside of the machine until the two Tooling Rail Spacers “D” contact the face of the Fixed Mount Rail.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 47: Tooling Rail Identification Figure 48: R1 Tooling Rail Spacers 8. Continue installing the remainder of the right and left tooling rails in sequence as described above. Special Instructions for the SS100, SS150, SS450, and BP Profiles: The Left #1 Tooling Rail Assembly (L1-1) for these profiles can be mounted in one of two possible positions based on the required height of the male leg.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE (Figure 49). When mounting the Tooling Rail Assembly for use with the SS100, SS450, or BP 1" profiles push it toward the center of the machine until the Tooling Rail Backstops "E" contact the Left Side Fixed Mount Rail #1 (Figure 49). Once it is positioned properly, tighten the two Mounting Bolts "F" using a 1/2" wrench. Figure 49: L1-1 Special Instructions 9. Loosen the two “A” Bolts on the Right Entry Guide (Figure 50).
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 50: Entry Guide Alignment Notches and Pins 13. Using the Tooling Rail Adjustment Handle (Figure 51), align the notch on the tooling rail marker plate to the alignment pin (Figure 25 on page 38) located in the Left Entry Guide. Make sure to choose the notch that corresponds to the desired leg configuration as noted on the decal on the marker plate. Turning the handle clockwise moves the tooling out-ward, turning it counter-clockwise moves move it in-ward.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 52: Marker Plate Notch and Pin 15. Load the reeled coil onto the machine using a fork lift or other rated lifting device. 16. Cut a 1” triangle of material off the 2 leading corners of the coil and feed it into the entry guides.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE 17. Start the machine and use the Jog button on the Manual Control Box or Computer to jog the material through the machine 6 to 8 inches at a time until it exits the last forming stations, and is about 1” from the Bead Roller Assembly (Figure 54). Figure 54: Jogging Material thru Machine CAUTION: Always make sure your machine is shut down prior to making any adjustments. DO NOT reach through the opening of the shear while the machine is running.
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE 19. Loosen the Slide Lock Bolts “D” on the top and bottom bead assemblies (Figure 21) and slide each bottom and top roll assembly left or right to center them on the 4” and 8” marks on the panel. 20. Lock the two top bead assemblies in the correct position by tightening the “D” bolt on each assembly (Figure 21).
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE Figure 57: Remove Shear Bolts 23. Remove the two “C” bolts from the slotted holes on the entry male and female shear die assemblies as described previously. 24. Locate the shear dies that correspond to the profile you have just installed. Separate the male and female entry and exit shear dies. 25. Set the Male Entry Die on top of the Bottom Die (Figure 20 - Detail A on page 32).
CHAPTER 15 PROFILE CHANGEOVER PROCEDURE 30. Start the machine again and slowly jog the panel approximately 6” past the exit die and stop. Again, TURN THE MACHINE OFF. 31. Adjust the male and female exit dies so that they are offset to the outside of the entry die by approximately 1/64” and lock down the two “C” bolts (Figure 58) on each assembly. This offset is necessary so that after a cut is made, the leading edge of the panel does not hang up on the exit die. Figure 58: Exit Die Adjustment 32.
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 59: SSQ100 Roller System 63
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 60: SS100 Panel Profile 64
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 61: SSQ150 Roller System 65
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 62: SS150 Panel Profile 66
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 63: SSQ200/210A Roller System 67
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 64: SS200 Panel Profile 68
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 65: SS210 Panel Profile 69
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 66: SSQ450/450SL Roller System 70
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 67: SS450 Panel Profile 71
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 68: SS450SL Panel Profile 72
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 69: SSQ550 Roller System 73
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 70: SS550 Panel Profile 74
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 71: SSQ675 Roller System 75
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 72: SS675 Panel Profile 76
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 73: FFQ100 Roller System 77
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 74: FF100 Panel 78
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 75: FFQ150 Roller System 79
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 76: FF150 Panel Profile 80
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 77: SSQBP Roller System 81
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 78: BP 1” Panel 82
CHAPTER 16 ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS Figure 79: BP 1 1/2” Panel 83
CHAPTER 17 RUN OUT TABLES AND REMOTE LIMIT SWITCH RUN OUT TABLES AND REMOTE LIMIT SWITCH The Run-Out Table (Figure 80 & Figure 81) attaches to the Exit End of the Shear assembly, and is used to support the panel as it exits the machine. It is available in 10 ft. long sections that fasten together, and have adjustable legs so they can be set to the correct height. The Remote Limit Switch (Figure 7 on page 14) is designed to be used with the run out tables for controlling panel length. 1. 2. 3. 4. 5.
CHAPTER 17 RUN OUT TABLES AND REMOTE LIMIT SWITCH Figure 80: Run Out Table 85
CHAPTER 17 RUN OUT TABLES AND REMOTE LIMIT SWITCH Figure 81: Run Out Table Setup 86
CHAPTER 18 QUICK CHANGE POWER PAC QUICK CHANGE POWER PAC The Quick Change Power Pac for your machine allows you to change from one power source to another very quickly. For example, it is useful for people who need to run their machine at the jobsite with a gas engine and use it in a factory or indoor setting as well. It requires two people to lift the Power Pac out of and into the machine. To change the power pac see below. Refer to Figure 82 POWER PAC REMOVAL 1.
CHAPTER 18 QUICK CHANGE POWER PAC Figure 82: Cable Connections and Fasteners 88
CHAPTER 19 TROUBLESHOOTING TROUBLESHOOTING The hydraulic system operates the Shear and Drive assemblies. They are interfaced together and electronically activated. The hydraulic system pressure is factory set at 2000 psi and should not be changed. Some of the common problems that occur and their solutions follow below. 1. Shear travels to the bottom of the stroke and does not return to the top of the stroke.
CHAPTER 19 TROUBLESHOOTING 2. Shear travels to the bottom of the stroke and returns to the top of the stroke without cutting the panel completely through. SOLUTION: Press and hold the Green Shear Down Button until the panel is cut off. Remove the cut panel and jog material out 2 or 3 inches past the shear. Adjust the pressure switch (Figure 83) by turning the silver knurled sleeve “A” clockwise 1/8 of a turn. Press the Shear Down Button again. Check to see if the panel is cut off completely.
CHAPTER 19 TROUBLESHOOTING Figure 84: Limit Switch Adjustment 4. After making a cut, the male or female leg of the next panel gets caught on the exit shear die and damages the panel. SOLUTION: This problem normally shows up after making a roller system/shear die change. The entry dies both male and female should be as close to the vertical leg of the panel as possible without touching.
CHAPTER 19 TROUBLESHOOTING SOLUTION #2: Make sure that the shear blades and dies are well lubricated on both sides with the proper lubricant (See GENERAL MAINENANCE on page 6). 6. Manual Control Panel buttons do not work. SOLUTION #1: Check fuse inside of Manual Control Box. Replace if blown with a 10-amp time delay fuse (Figure 8 on page 15). SOLUTION #2: If you have a gasoline engine, check the condition of the battery. The control system requires 12 volts to operate properly.
APPENDIX A PLC CONTROLLER PLC CONTROLLER Figure 85: PLC Assembly Figure 86: Serial Number Plate A-1
APPENDIX A PLC CONTROLLER Home When the controller is turned on, it will automatically go to the home screen. Figure 87: Home Screen Manual Operation The machine can be manually operated from the home screen by pressing the Jog and Shear buttons. JOG: FWD and REV JOG buttons will jog the machine forward and reverse as long as the button is depressed. When the JOG buttons are released, the action will stop.
APPENDIX A PLC CONTROLLER Pre-Run Sequence: 1. 2. Jog the material forward using the manual FWD JOG or MICRO buttons on the Home screen or the JOG switch at the entry end of the machine. The material must exit the shear and be detected by the panel detection sensor. Shear the material using the Shear Cycle button. At that point, the machine will be fully loaded with material, the length counter will be reset and the controller will be ready to run in automatic mode.
APPENDIX A PLC CONTROLLER programmed after the current job, the controller will stop and return to the Job Entry screen. Clear Jobs To clear the current job on the screen press Clear Job. To clear all the jobs in the controller, press Clear All. The next screen will confirm the Clear All command, press Yes to clear all jobs. Auto Run Press the Run Mode button to run the jobs that are programmed. Type in the job number to run first (if different than the job that was just programmed).
APPENDIX A PLC CONTROLLER Automatic Operation In the Auto Run screen, the current job and progress are displayed. Press the Start button to begin running the job. When the current job is complete the next job will start if the No button for pause was pressed for the current job. If the Yes button was pressed for pause or if there is no next job programmed, the controller will return to the Job Entry screen after the current job is completed.
APPENDIX A PLC CONTROLLER Figure 92: Calibration Screen The controller will display the theoretical length of the part after it is produced. The theoretical length may be slightly different than the intended calibration length due. Measure the length of the part and input the length in the Actual Measured Length fields. Press Enter to re-calibrate the controller or Cancel to return to the Home screen without making any changes to the controller.
APPENDIX A PLC CONTROLLER Figure 94: Setup Screen In the Setup screen, the Units of Measure can be changed to Imperial units in either feet and inches (ft/in) or only inches (in) or Metric units (mm). Example: ft/in: 10’ 4 1/16” in: 124 1/16” mm: 3,151mm The shear operation can be turned on and off if an auxiliary shear such as the Swenson Snap Table will be utilized. The brightness of the display can also be adjusted up or down by pressing the right and left arrow buttons.
APPENDIX A PLC CONTROLLER The Status 1 screen shows the condition of the Hydraulic Pressure Switch and the Top of Stroke Limit Switch. If one or both of the TOS Shear Limit Switches are not activated the TOS Shear Limit Switch light will be on. Refer to the Shear section in the machine manual for limit switch adjustment. If the motor is not on or if the pressure switch is not activated then the Hydraulic Motor light will be on. The Status screen lists the Encoder Wheel Circumference.
APPENDIX A PLC CONTROLLER Coil Tracking: From the Home screen, press the Coils button to change the coil of material to track. If the security is turned on, a password must be entered if changes to the stored coils are necessary. If security is turned off, the controller will display the current coil screen and changes can be made without the password. Figure 97: Coils Password Access Screen Without the password, press Continue to view the Coils screen.
APPENDIX A PLC CONTROLLER Example: The controller is set to run a black coil designated as Coil #2 and the user changes to a white coil designated by Coil #1. From the Home screen, press the Coils button which will bring up the Coil #2 information. Press the Coil #1 button and then the Home button. If the remaining length reads negative then the machine has tracked more material than the purchased length.
APPENDIX A PLC CONTROLLER Figure 100: Coils Color Screen Coil Length Calculator The controller has a built in calculator to estimate the length of a coil based on the dimensions of the coil. From the Coils screen, press Length Calculator button. Figure 101: Length Calculator Screen Press the Select Material button to select the thickness and type of material.
APPENDIX A PLC CONTROLLER Figure 102: Material and Thickness Screen Then enter in the Inside Diameter of the Coil, Width of the coil and thickness of the coil. The thickness of the coil is the difference between the Inside Diameter (ID) and the Outside Diameter (OD). When all the fields are populated, the calculator estimates the length of the coil. Press the Done button to return to the Coils screen.
APPENDIX B ELECTRICAL SCHEMATICS ELECTRICAL SCHEMATICS Drawing Number PLC-380-000 PLC-380-000 Sheet Number 1 2 Description Electrical Assembly – Parts List Electrical Assembly – Wiring Details PLC-381-000 PLC-381-000 PLC-381-000 PLC-381-000 PLC-381-000 1 2 3 4 5 Control Box Assembly – Parts List Control Box Assembly – Outside & Inside Views Control Box Assembly – Wiring Schematic Control Box Assembly – Ladder Logic 1 Control Box Assembly – Ladder Logic 2 B-1
Parts List ITEM QTY PART NUMBER 7 TITLE 1 1 ELC-300-138 GROMMET, 3/4" ID, 1-1/2" OD 2 1 FAS-HC5-118 HEX HEAD CAP SCREW, 1/4-20 x 1" LG. 3 2 FAS-HC5-278 HEX HEAD CAP SCREW, 1/4-20 x 2" LG.
MAIN CONTROL BOX 125 109 102 N.C. GND REV FOR SHEAR DOWN EMERGENCY STOP START FEED 108 N.O. 124 N.O. N.C. 113 SHEAR UP 85 N.O. N.O. (+) 116 N.C. N.C. 96 122 COMPONENTS 121 107 N.O. 117 PANEL LENGTH 119 BLK BLU 124 (-) N.C. 97 N.O. UP B 112 REV B SHEAR MOTOR DOWN A (-) 22 WHT BRN 96 FWD A 72 GND WHT BRN 97 GRN (-) ENTRY END/REMOTE CONTROL BLK 123 70 N.C. 104 84 N.O. (-) 20 WHT (+) STOP FEED JOG-RUN MOTOR START BLK BLU REMOTE JOG N.O.
PARTS LIST QTY 1 34 PART NUMBER ELC-100-006 TITLE 2 3 ELC-100-007 DIN RAIL STOP (NOT SHOWN) 3 12 ELC-100-008 TERMINAL BLOCK JUMPER (NOT SHOWN) 4 1 ELC-100-017 FEMALE CLOSURE CAP 5 1 ELC-100-018 MALE CLOSURE CAP 6 1 ELC-100-021 ENCLOSURE 7 6 ELC-100-025 RECEPTACLE, 4 PIN MALE x.5M 8 1 ELC-100-026 RECEPTACLE, 5 PIN MALE x.5M 9 1 ELC-300-101 FUSEHOLDER BUS HKP 10 3 ELC-300-103 PUSH BUTTON, GREEN 11 1 ELC-300-104 SELECTOR SWITCH, W/1 N.O.
B A 1 A 1 4 2 5 3 6 33 22 9 12 21 7 17 31 33 36 26 B 23 28 29 SECTION B-B LENGTH: 42" FROM STRAIN RELIEF 29 6 27 24 33 29 24 28 25 LENGTH: 24" FROM STRAIN RELIEF MATERIAL LENGTH NEW TECH MACHINERY CORP. FINISH SEE BOM TO ATTACH TERMINAL BLOCK MOUNTING PLATE TO ENCLOSURE REV REVISION HISTORY SECTION A-A ECR NO. DATE RELEASED BY TOLERANCES .XX = `.01 .XXX = `.
REV N.O. REMOTE FWD P1 COMM STOP SHEAR UP - DOWN P2 WHT N.O. 10 BRN GROUND TO BOX 117 11 BLK 12 N.C. BLU N.C. GRY 14 -NEG BRN (-) +POS WHT -NEG BLU +POS BLK GRD 01 GRD 22 02 408 118 03 411 40 404 04 72 120 05 11 405 06 10 70 121 07 106 113 61 08 412 104 09 12 114 103 10 122 14 11 403 123 13 4 22 (-) 1 20 N.O. N.O. 121 N.O. 122 104 123 TOS LS RIGHT P4 HYDRAULIC ON P.S. P5 BOS P.S. P6 N.O. BRN N.C. WHT N.C. BLU N.O. BLK N.C.
LINE 1000 FROM QCPP +12V E-STOP F1 128 83 127 125 TO LINE 1006 102 N.C. 10A 1001 LEGEND 1 WIRE NUMBER 2 PIN NUMBER FUSE 1002 QCPP GROUND 80 1003 PANEL LENGTH GROUND 95 MUSHROONM HEAD PUSH BUTTON (N.O.) MUSHROONM HEAD PUSH BUTTON (N.C.) QCPP-GAS KILL SWITCH 85 N.O. CONTACT (N.O.) CONTACT (N.C.) 126 GRD 1004 LOCATE GRD TOP LEFT OF BOX FROM QCPP -12V 1005 1006 82 101 +12V FROM LINE 1000 100 PUSH BUTTON (N.O.) 411 1007 PLC IN (TOS) 11 PUSH BUTTON (N.C.) LIMIT SWITCH (N.O.
FROM LINE 1019 FROM LINE 1019 LINE 1020 +12V -12V T.O.S. LEFT 1021 31 32 N.C. LEGEND 1 WIRE NUMBER 2 PIN NUMBER FUSE MUSHROONM HEAD PUSH BUTTON (N.O.) MUSHROONM HEAD PUSH BUTTON (N.C.) 7 110 409 20 SO2 PLC OUT (SHEAR UP) 124 1023 SHEAR UP SHEAR DOWN CR2 116 1024 4 3 109 N.O. N.C. SHEAR DOWN N.O. 308 1025 8 408 22 SO1 PLC OUT (SHEAR DOWN) 1026 HYD ON SHEAR 115 1027 1 CR2 8 105 PUSH BUTTON (N.C.) B.O.S. 52 53 63 N.O. 1 51 3 8 CR3 N.O. CR3 1029 HYD ON N.
